Apparatus and method for manufacturing a roll of crimped filling material for rod-like articles

ABSTRACT

The object of the application is an apparatus for manufacturing a roll of crimped filling material for rod-like articles, comprising a unit (4) for feeding a continuous strand of the filling material and a crimping unit (5) for crimping the filling material. The apparatus is characterised in that between the unit (4) for feeding the continuous strand of the filling material and the crimping unit (5) there is a cutting unit (23) for cutting the continuous strand of the filling material (20) into sections (22), and in that the crimping unit (5) is adapted to crimp the cut-off section (22) of the filling material transversely to the direction of movement of the material section (22). The apparatus is further characterised in that the forming unit (16, 46, 51, 61) is adapted to form a roll (22X, 22Y) from the cut-off crimped section (22) of the filling material in the form of a substantially cylindrical rod. The object of the application is also a method for manufacturing a roll of crimped filling material for rod-like articles.

The object of the invention is an apparatus and a method for manufacturing a roll of crimped filling material for rod-like articles.

In the tobacco industry, various smoking articles filled with tobacco material and filter material are manufactured. Mouthpieces filled with a single type of filter material or with different types of materials may contain materials made from sections cut off from strips or sheets, the sections being suitably crimped. The crimping, depending on the type of material subjected to such process, may for example increase the absorption or the supporting surface of the material so as to give it sufficient volume to densely fill the wrapper and effectively filter the flowing smoke. In the crimped filling material formed into a cylindrical rod, a network of channels allowing the air to flow is formed. Furthermore, the crimping of the tobacco itself as filling material allows increasing the surface being in contact with the flowing air, which stimulates the release of aromatic substances into the flowing air.

Apparatuses and methods for forming a crimped material used as a filling for rod-like articles of the tobacco industry are known in the prior art. For example, in the publication US2001709 there is disclosed a method of forming a continuous rod with a longitudinally crimped filter material filling. The crimping is carried out by means of a unit of crimping rollers forming an arrangement of longitudinal crimps facilitating the arrangement of the filling material in the wrapping material forming the continuous rod. Another example of the manufacture of longitudinally pressed rolls is disclosed in the publication US2164702A which discloses a system for crimping the filling material of rod-like articles of the tobacco industry wherein a continuous rod adapted for further cutting into individual rods is formed. The publication discloses a continuous process for forming a continuous rod using pressing in a direction longitudinal to the direction of forming the continuous rod.

In solutions known from the prior art, longitudinal crimping of a continuous strand of a filling material is used, as a result of which an n-number of crimps is performed simultaneously, and the control of the crimping process as well as the subsequent forming of a roll from the crimped material are difficult. The present invention addresses the need to find a solution to facilitate the process of crimping and forming the crimped material into a cylindrical rod ready to be wrapped with a wrapper.

The object of the invention is an apparatus for manufacturing a roll of crimped filling material for rod-like articles, comprising a unit for feeding a continuous strand of the filling material and a crimping unit for crimping the filling material. The apparatus according to the invention is characterised in that between the feeding unit for feeding the continuous strand of the filling material and the crimping unit there is a cutting unit for cutting the continuous strand of the filling material into sections, and in that the crimping unit is adapted to crimp a cut-off section of the filling material transversely to the direction of movement of the material section. The apparatus is further characterised by comprising a forming unit adapted to form the roll from the cut-off crimped section of the filling material in the form of a substantially cylindrical rod.

Preferably, the apparatus is characterised in that the forming unit comprises a plurality of forming pockets.

Preferably, the apparatus is characterised in that the forming pockets are provided with swinging elements being cylinder sectors situated parallel to the axis of the forming pocket.

Preferably, the apparatus is characterised in that the forming pockets are placed on a drum conveyor.

Preferably, the apparatus is characterised in that that the forming pocket has a movable bottom.

Preferably, the apparatus is characterised in that the forming unit comprises a plurality of forming pockets on the drum conveyor, and further comprises a ring situated coaxially with the drum conveyor, the forming pocket being formed between the drum conveyor and the ring.

Preferably, the apparatus is characterised by further comprising a guiding unit for inserting a section of the filling material into the forming pocket.

Preferably, the apparatus is characterised by further comprising a feeding unit adapted to place a section of wrapping material into the pocket before forming a rod-like article from the cut-off section of crimped filling material and the section of the wrapping material.

Preferably, the apparatus is characterised in that the wrapping material section is held in the pocket by means of a vacuum.

Preferably, the apparatus is characterised by further comprising a guiding unit adapted to placing the cut-off section of the crimped filling material into the formed section of the wrapping material.

Preferably, the apparatus is characterised in that the cutting apparatus is provided with rotary knives and a supporting roller.

The object of the invention is also a method for manufacturing a roll of crimped filling material for rod-like articles wherein a continuous strand of the filling material is fed by means of a filling material feeding apparatus. The method according to the invention is characterised in that the filling material is cut into sections by means of a cutting unit for cutting the continuous strand of the filling material into sections, after which the cut-off sections of the filling material are crimped by means of a crimping unit. The method is also characterised in that a roll in the form of a substantially cylindrical rod is formed from the cut-off section of crimped filling material.

Preferably, the method is characterised by comprising a step wherein sections of wrapping material are placed in the forming unit before forming the rod-like article from the cut-off section of crimped filling material. The method is further characterised in that after forming the rod-like article from the cut-off section of crimped filling material, the rod-like article is wrapped with the wrapping material section.

Preferably, the method is characterised by comprising a step wherein the rod-like article formed from the cut-off section of crimped filling material is placed in a pre-formed wrapping material section.

The solution according to the invention is an alternative to apparatuses and methods for crimping and forming individual rolls of filling material of the rod-like articles known from the prior art. In addition, the elimination of the process of forming a continuous rod allows to significantly reduce the space occupied by the apparatus.

The invention is described below with reference to embodiments shown in the drawing in which:

FIG. 1 shows a front view of an apparatus in the first embodiment,

FIG. 2 shows an expanded view of lateral surfaces of drum conveyors of FIG. 1 ,

FIG. 3 shows a front view of an apparatus in the second embodiment,

FIG. 4 shows an expanded view of lateral surfaces of drum conveyors of FIG. 3 ,

FIG. 5 shows a front view of an apparatus in the third embodiment,

FIG. 6 shows a front view of an apparatus in the fourth embodiment,

FIG. 7 shows a front view of an apparatus in the fifth embodiment, and

FIG. 8 shows a feeding unit for feeding a filling material.

The apparatus 1 for manufacturing rod-like articles shown in the first embodiment in FIG. 1 comprises a first drum conveyor 2, a feeding unit 3 for feeding a wrapping material, a feeding unit 4 for feeding a filling material, a crimping unit 5 for crimping the filling material, a forming unit 6 for forming a roll of the filling material, a pushing unit 7 for moving the filling material together with the wrapping material, and a second drum conveyor 8 for conveying finished rod-like articles. The wrapping material in the form of a strand 10 is unwound from a roll 11 of the wrapping material and cut into sections 12 by means of a cutting apparatus 13 provided with rotary knives 14 and a drum 15 whose lateral surface constitutes a supporting surface for the knife 14. The strand 10 and the sections 12 of the wrapping material are held on the rotary drum 15 by means of a vacuum. The rectangular section 12 of the wrapping material after cutting is fed onto the first drum conveyor 2 so that the section 12 is laid partly in a groove 16 of such conveyor and partly on a surface adjacent to the groove 16. The section 12 of the wrapping material is held on the drum conveyor by means of a vacuum. The filling material in the form of a strand 20 is unwound from the roll 21 of the filling material and cut into sections 22 by means of a cutting apparatus 23 provided with rotary knives 24 and a supporting roller 25. The rectangular section 22 of the filling material, after being cut off, is fed to the crimping unit 5 provided with two grooved crimping rollers 26 and 27. The rollers 26 and 27 are adapted to crimp the filling material transversely to the direction of movement of the section 22 of the filling material. The crimped rectangular section 22 of the filling material is placed in the form of a roll 22X in a recess of the section 12 of the wrapping material lying partly in the groove 16, the groove 16 being a forming unit. As the drum conveyor 2 rotates, the pre-formed filling material, i.e. the roll 22X, passes through the operating area of the forming unit 6 provided with a rotating forming roller 28 which rotates synchronously with the drum conveyor 2 so that the longitudinal groove 29 presses the filling material into the wrapping material 12 and into the bottom of the groove 16. Compressed air nozzles 30 directed at the lateral surface 2A of the drum conveyor 2 may be used to lift and bend the edge 12A of the wrapping material section 12. Coaxially with the drum conveyor 2, there is situated a drum conveyor 8 (in FIG. 1 behind the drum conveyor 2) which is provided with the same number of grooves 32 as the drum conveyor 2, whereas the drum conveyor 8 may be integrated with the conveyor 2. As shown in an expanded view of the lateral surfaces 2A and 8A of such conveyors in FIG. 2 , the groove 16 is coaxial with the groove 32. Directly opposite the groove 16, a pusher 33 driven by an actuator 34 is situated. The task of the pusher 33 is to move the roll 22X together with the section 12 of the wrapping material along the groove 16. FIG. 2 shows several rolls 22X in the successive grooves 16 of the drum conveyor 2 wrapped in the sections 12 of the wrapping material which are collectively referred to as an intermediate product 35. For the intermediate product 35 being moved along the groove 16, the edge 12A is wrapped and the wrapping of the second edge 12B begins, the intermediate product 35′ being further moved along the groove 16. The process of wrapping the edge 12B of the intermediate product 35′ is assisted by a profiled element 36. A rod-like article 37 which has been completely wrapped with the wrapping material occupies its final position as shown in the groove 32′. Further, the rod-like article 37 may be transferred for further processing or transferred to a storage.

The apparatus 1′ for manufacturing rod-like articles shown in the second embodiment in FIG. 3 comprises a first drum conveyor 38, a feeding unit 4 for feeding the filling material, a crimping unit 5 for crimping the filling material, a forming unit 6 for forming a roll of the filling material, a pushing unit 7 for moving the roll of the filling material and, a second drum conveyor 40 for conveying finished rod-like articles. The filling material in the form of a strand 20 is unwound from a roll 21 and cut into sections 22 by a cutting apparatus 23 provided with rotary knives 24 and a supporting roller 25. The rectangular section 22 of the filling material after cutting is fed to the crimping unit 5 provided with two grooved rollers 26 and 27 through a slotted guiding unit 50. The rectangular section 22 of the filling material after crimping is placed in the form of a roll 22X in a groove 39. As the drum conveyor 38 rotates, the partially formed filling material, i.e. the roll 22X of crimped filling material, passes through the operating area of the forming unit 6 provided with a rotating forming roller 28 which rotates synchronously with the drum conveyor 2 so that the longitudinal groove 29 of the forming roller 28 presses the filling material into the bottom of the groove 39. Coaxially with the drum conveyor 38, there is situated a drum conveyor 40 (in FIG. 3 behind the drum conveyor 38) which is provided with the same number of grooves 41 as the drum conveyor 38, whereas the drum conveyor 40 may be integrated with the drum conveyor 38. As shown in an extended view of lateral surfaces 38A and 40A of such conveyors in FIG. 4 , the groove 39 is coaxial with the groove 41. Directly opposite the groove 39, a pusher 33 driven by an actuator 34 is situated. The task of the pusher 33 is to move the roll 22X along the groove 39 and further into a thin-walled paper or cardboard tube 42. The thin-walled tubes 42 are supplied from a not shown container to the grooves 41 where they are held by a vacuum. FIG. 4 shows several rolls 22X in the successive grooves 39 of the drum conveyor 38 in successive phases of moving the roll 22X into the thin-walled tube 42. The groove 41′ holds a finished rod-like article 43 comprising the tube 42 and the roll 22X of the filling material inserted therein. The rod-like article 43 may be transferred for further processing or transferred to a storage.

The apparatus 1″ for manufacturing rod-like articles shown in the third embodiment in FIG. 5 comprises a drum conveyor 45, a feeding unit 4 for feeding the filling material, a crimping unit 5 for crimping the filling material, a forming unit 46 for forming a roll of the filling material, a pushing unit 7 for moving a roll 22X of the filling material, and a second drum conveyor 40 for conveying finished rod-like articles. The filling material is fed and crimped in the same manner as in the preceding embodiments. The rollers 26 and 27 feed the crimped section of the filling material directly into the pockets 47 of the forming unit 46. The forming unit 46 comprises a plurality of pockets 47 on a lateral surface 45A of the drum conveyor 45. The rectangular section 22 of the crimped filling material is fed by a slotted guiding unit 50 situated beneath the crimping unit 5 and is placed in the form of the roll 22X in the pocket 47. The forming pocket 47 on the drum conveyor 45 is provided with self-aligning elements 48, 49 which are cylinder sectors situated parallel to the axis of rotation of the drum conveyor 45.

The apparatus 1‴ for manufacturing rod-like articles shown in the fourth embodiment in FIG. 6 comprises a drum conveyor 53, a first feeding unit 4 and a second feeding unit 4′ for feeding a filling material, a first crimping unit 5 and a second crimping unit 5′ for crimping the filling material, a feeding unit 57 for feeding an insert 59, a forming unit 51 for forming a roll of the filling material, a pushing unit 7 for moving a bundle 60 of rolls of filling material and insert sections, and a second drum conveyor 40 for conveying finished rod-like articles. The filling material is fed and crimped in the same manner as in the preceding embodiments. The rollers 26 and 27 of the first crimping unit 5 feed the crimped section 22 of the filling material directly into a pocket 52 of the forming unit 51. The forming unit 51 comprises a plurality of pockets 52 on a lateral surface 53A of the drum conveyor 53. The pocket 52 is formed by lateral walls of the groove 54 and a movable bottom 56 (the drive of this element is not shown) moving in the groove 54 and by swinging elements 48, 49 as in the third embodiment. The rectangular section 22 of the filling material after crimping is fed by a slotted guiding unit 50 situated beneath the crimping unit 5 and is placed in the form of a roll 22X in the pocket 52. Further, the feeding unit 57 feeds a single longitudinal insert which is placed on the roll 22X placed on the bottom 56. In a further step, the crimped section 22 of the filling material is fed by the second crimping unit 5′ in the form of a roll 22Y. The roll 22Y is placed on the roll 22X and the insert 59. Together, the rolls 22X, 22Y and the insert 59 form the bundle 60 to be moved onto an adjacent drum conveyor.

The apparatus 1⁗ for manufacturing rod-like articles shown in the fifth embodiment in FIG. 7 is provided with a forming unit 61, which comprises a drum conveyor 62 and a coaxially mounted ring 63 between which forming pockets 64 are situated. On a lateral surface 62A of the drum conveyor 62 there are lower portions of the forming pockets 64, while in the ring 63 there are upper portions of the forming pockets 64. The forming pocket 64 is provided with a slotted inlet 65. A filling material roll 22X is fed into the forming pocket from the crimping unit 5 through the slotted guiding unit 50 and the slotted inlet 65.

FIG. 7 shows an embodiment of a feeding apparatus 4′ for feeding a filling material. The feeding apparatus 4′, similarly to the feeding apparatus 4, is adapted to unwind the filling material, for example a tobacco material, from the roll 21 by means of knives 24 in the cutting apparatus 23. The cut-off section 22 of the filling material is turned by means of a turning apparatus 44 into a position shown as 22′. This is followed by crimping in the crimping apparatus 5 in a similar way as described above. 

1. An apparatus for manufacturing a roll of crimped filling material for rod-like articles, comprising a unit (4) for feeding a continuous strand of the filling material, and a crimping unit (5) for crimping the filling material, characterised in that between the unit (4) for feeding the continuous strand of the filling material and the crimping unit (5) there is a cutting unit (23) for cutting the continuous strand of the filling material (20) into sections (22), and in that the crimping unit (5) is adapted to crimp a cut-off section (22) of the filling material transversely to the direction of movement of the material section (22), and in that it further comprises a forming unit (16, 46, 51, 61) adapted to form a roll (22X, 22Y) from the cut-off crimped section (22) of the filling material in the form of a substantially cylindrical rod, further characterised in that the forming unit (46, 51, 61) comprises a plurality of forming pockets (47, 52, 64); further characterized in that the forming pockets (47, 52) are provided with swinging elements (48, 49) being cylinder sectors situated parallel to the axis of the forming pocket (47, 52).
 2. (canceled)
 3. (canceled)
 4. The apparatus as in claim 2 characterised in that the forming pockets (47, 52, 64) are placed on a drum conveyor (45, 53, 62).
 5. The apparatus as in claim 2 characterised in that the forming pocket (52) has a movable bottom (56).
 6. The apparatus as in claim characterised in that the forming unit (61) comprises a plurality of forming pockets (64) on the drum conveyor (62), and further comprises a ring (63) situated coaxially with the drum conveyor (62), the forming pocket (64) being formed between the drum conveyor (62) and the ring (63).
 7. The apparatus as in claim characterised by further comprising a guiding unit (50) for inserting a section (22) of the filling material into the forming pocket (16, 47, 52, 64).
 8. The apparatus as in claim characterised by further comprising a feeding unit (3) adapted to place a section (12) of a wrapping material in the pocket (16) before forming a rod-like article from the cut-off section (22) of crimped filling material and the section (12) of the wrapping material.
 9. The apparatus as in claim 8 characterised in that the wrapping material section (12) is held in the pocket (16) by means of vacuum.
 10. The apparatus as in claim characterised by further comprising a guiding unit (50) adapted to placing the cut-off section (22) of the crimped filling material into the formed section (12) of the wrapping material.
 11. The apparatus as in claim characterised in that the cutting apparatus (23) is provided with rotary knives (24) and a supporting roller (25).
 12. A method of manufacturing a roll of crimped filling material for rod-like articles wherein a continuous strand of the filling material is fed by means of a filling material feeding apparatus, characterised in that the filling material is cut into sections by means of a cutting unit for cutting the continuous strand of the filling material into sections, then the cut-off sections of the filling material are crimped by means of a crimping unit, and then a roll in the form of a substantially cylindrical rod is formed from the cut-off section of crimped filling material; further comprising a step wherein: the rod-like article formed from the cut-off section of crimped filling material is placed in a pre formed wrapping material section.
 13. The method as in claim 12 characterised by comprising a step wherein: sections of wrapping material are placed in the forming unit before forming the rod-like article from the cut-off section of crimped filling material, and after forming the rod-like article from the cut-off section of crimped filling material, the rod-like article is wrapped with wrapping material section.
 14. (canceled) 